Multi-set rectangular copper hairpin windings for electric machines

ABSTRACT

An electric machine having multi-set rectangular copper hairpin windings comprises a stator having a plurality of partially closed stator slots. A first winding set and a second winding set are positioned in the stator slots. The first winding set and the second winding set are connected by adjacent leg ends. According to a first embodiment, conductor layers in alternate slots alternate between different phases. The conductor layers in the remaining slots are all of the same phase. Hairpins having unequal length legs are used to implement the first embodiment. According to a second embodiment, conductor layers in alternate slots include one phase for the first winding set and another phase for the second winding set. The conductor layers in the remaining slots are all of the same phase. Hairpins having equal length legs are used to implement the second embodiment.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Ser. No. 10/438,429, filedMay 15, 2003 now U.S. Pat. No. 6,894,417, which claims the benefit ofU.S. Ser. No. 60/380,638, filed May 15, 2002.

BACKGROUND

1. Field

This invention is related to winding technology of electric machines,and particularly hairpin wound electric machines.

2. Background Discussion

Electric machines are key components of conventional automobiles. Someelectric machines serve as starting motors to crank automobile engines.Other electric machines serve as alternators that generate electricityfrom engine motion and deliver power to automobile loads. Electricmachines are also very important in modern hybrid electric vehicles(HEVs) that combine an internal combustion engine with an electric drivesystem powered by a battery bank. In these hybrid vehicles, a singleelectric machine is typically required to operate as (a) a startermotor, (b) an electric drive assist (propulsion boost) as well as pureelectric drive (propulsion), (c) a generator providing electric powerfor onboard electric loads and charging the battery banks, and (d) are-generator acting to convert the kinetic energy of the vehicle toelectric power for charging the battery bank during braking/decelerationof the vehicle.

Hybrid Electric Vehicles can operate with low fuel consumption and lowair-pollution. There are two propulsion systems onboard the HEV: (i) thetraditional diesel/gasoline engine and (ii) the electric drive system.The additional electric drive system consists of battery bank (energystorage component), power electronics unit (control components) andelectric machine (conversion component—electrical to mechanical energy).The electric drive system provides propulsion and power generation aswell as power regeneration.

The electric machine is a core component in the HEV's electric drivesystem. Based on driving schedule/requirements, the machine will rununder the motoring state during vehicle starting, electric assistdrive/propulsion or pure electric drive/propulsion. The electric machineis required to operate under the normal generating state during enginedrive/propulsion (thereby charging batteries) and the re-generatingstate during vehicle braking. Obviously the efficiency of the electricmachine will directly govern the efficiency of electric drive system andconsequently the fuel economy of the vehicle.

As the power conversion component in an electric drive system, theelectric machine interacts directly or indirectly (through a belt ormechanical converter/clutch) with the drive shaft or engine shaft andhas to be located ‘under the hood’ of the vehicle. The space availablefor the electric machine in the required location is limited. Therefore,the size/dimensions of the electric machine must be as small aspossible. Compared to other applications for electric machines, highefficiency and small size are more important to the electric machineonboard the HEV. However, automobile manufacturers are increasinglycalling for high efficiency and small size for almost all electricalmachine applications in vehicles. Therefore, the need for small andmid-sized electric machines having high efficiency and small size isapplicable to all automotive vehicles, and is particularly applicable toHEVs and purely electric vehicles.

One way to reduce the size of an electric machine and increaseefficiency is to increase the slot-fill-ratio of the electric machine.With reference to FIGS. 1( a) and 1(b), small and mid-sized electricmachines include a stator 26 formed from a lamination stack. A pluralityof slots 20 are formed in the stator. The stator slots are arranged in acircular fashion around the stator with an opening 22 to the slot thatfaces the rotor of the electric machine. The slots 20 of these electricmachines are deemed “partially closed” or “semi-closed” because a neck28 is formed near the opening to each slot, such that the width of theopening 22 is smaller than the width of the slot itself. A plurality ofelectric conductors 24, typically in the form of copper wires, arepositioned in the slots of the stator.

As mentioned in the preceding paragraph, to design an electric machinewith high efficiency and small volume, a high slot-fill-ratio (SFR) ispreferred. The term “slot-fill-ratio” is typically defined as the ratioof (a) the aggregate cross-sectional area of the bare copper conductorsin a slot to (b) the cross-sectional area of the slot itself. With highSFR, the large cross-sectional area of the copper wires helps reduce thephase resistance and consequently the resistance of the windings (i.e.,power loss) for a given slot size, so the efficiency of the machine isimproved. Accordingly, more efficient electric machines can be built ata smaller size than less efficient predecessors.

Armature windings of most small and mid-sized electric machines aretypically wound in many turns with single or multiple strands of roundmagnetic wire. FIG. 1( b) shows an exemplary prior art stator slothaving a plurality of round conductors in the stator slot. The SFR ofthe round wire machines can reach a maximum of 44% preventing the designof low loss (resistance), high efficiency electric machines. Asdiscussed previously, this issue becomes even more critical whendesigning high efficiency machines for hybrid vehicles. Available spaceonboard hybrid vehicles is strictly limited, and therefore, boostingefficiency by increasing machine size becomes impractical.

One solution to increasing the SFR is to use rectangular wires in thestator slots in place of round wires, such as the arrangement shown inFIG. 1( a). Use of rectangular wires in the stator slots can increasethe slot-fill-ratio up to 70% over that of round wires, allowing the SFRof rectangular wire machines to reach near 75% or higher. Unfortunately,the phenomena known as “skin effect” limits the size of conductors thatmay be used in the stator slots, especially the thickness of theconductor in the slots. “Skin effect” reduces the effectivecross-sectional area of a conductor in a slot as the thickness of theconductor increases. Skin effect is especially prevalent in straightconductor segments at high speed operation. Accordingly, use ofrectangular wires can increase the SFR, but the thickness of eachrectangular wire relative to the slot height/depth has to be limited inorder to reduce the skin effect of the conductors. Because the leakageflux linkage at different height/depth levels of a conductor in a givenslot increases from the top to the bottom of the slot, the back EMFcorresponding to the lower part of the conductor becomes higher thanthat at the top part of the conductor.

The back EMF due to slot leakage flux forces a great amount of currentflow at the top part of the conductor. Accordingly, the current densityin the conductor in a slot increases from the bottom of the slot to thetop if all the conductors in the slot carry the same phase current asset forth in equation (1) below. If different phase currents are carriedin a slot, the current density exhibits a complicated distribution. Whenthe AC current flows in a conductor, skin effect will reduce theeffective cross-sectional area of the conductor so the AC resistance ofa conductor is larger than its DC resistance. The increase of ACresistance due to skin effect in rectangular slot depends on thepenetrated depth, d, of electromagnetic wave, i.e.,

$\begin{matrix}{d = \sqrt{\frac{b_{s}}{b_{c}}\frac{\rho}{\pi\; f\;\mu}}} & \lbrack {{equation}\mspace{14mu}(1)} \rbrack\end{matrix}$Where ρ is the resistivity of the conductor; ƒ is the frequency of theAC signal; μ is the permeability of the conductor (roughly equal to thepermeability of air for copper conductors), b_(c) and b_(s) are thewidths of the conductor and the slot, respectively. Obviously thepenetrated depth of electromagnetic waves will be reduced as frequencyincreases. Generally, there will be no current flowing at the lower partof the conductor in a slot if the thickness of the wire is triple thepenetrated depth. Therefore, the thickness of rectangular wires in theslot should be made as small as possible.

If several strands of wires are laid in a slot, the leakage back EMF ina strand in the lower part of the slot will be higher than the leakageback EMF in the strand in the upper part of the slot under the effect ofslot leaking flux. Circulating currents among the strands will beproduced due to the unequal leakage back EMFs if the strands are weldedtogether as one conductor at the end-turn segment, which will raise thepower loss. To reduce or eliminate the circulating current in largeelectric machines, the winding bars are often composed of many strandsof small/thin rectangular conductors whose positions are transitioned(such as 540° transitioned winding bar etc.) in the axial direction of aslot (see FIG. 2). Reducing the wire thickness in the stator slots helpsto lower the negative skin effect and assists in achieving highefficiency in an electric machine with rectangular conductors. However,these winding bars have to be laid in open slots requiring special slotwedges (normally a magnetic slot wedge to reduce skin and air-gapeffects). Because of this, such winding bars are too complicated toutilize in manufacturing of small and mid-sized electric machines, asthey would dramatically increase the difficulty and cost ofmanufacturing, and reduce the reliability of the machines, especially inhybrid vehicle applications. Furthermore, it is not desirable to useopen slots in many small and mid-sized electric machines. In middle andsmall size high frequency AC machines, Litz wires are often used for ACwindings. Litz wires can help reduce circulating current and skineffects of AC windings, but the slot-fill-ratio cannot be improved withLitz wires. On the other hand, the transition of AC windings should beperformed by a special design according to armature stack length inorder to eliminate circulating current within windings, simply pickingup available Litz wires may not reach the goal of eliminatingcirculating current. Furthermore, Litz wire windings are very difficultto handle during manufacturing, and would therefore contribute tomanufacturing costs and present additional manufacturing hurdles.

To simplify the manufacturing and the keep high slot-fill-ratio ofwindings, pre-formed rectangular wires have been formed having straightconductor segments that are positioned in the stator slots, but twistedends that form the end turns, as shown in FIG. 3. However, thepre-formed windings shown in FIG. 3( a) must be inserted through theslot opening to be inserted on the stator. Thus, these pre-formedwindings can only be placed in open slots like the AC windings of FIG. 2that are used for large electric machines. These windings can not beplaced in the partially closed slots typically used for small andmid-sized electric machines because the restricted opening in apartially closed slot prohibits the windings from entering the slot.

To solve this problem, designers of small and mid-sized electricmachines having partially closed slots have used conductor segments thatmay be inserted into the top and/or bottom of the slot and need not passthrough the slot opening. To this end, the conductor segments are firstbent into U-shapes, such that the conductor segments form a U-shaped endturn with two legs, such as that shown in FIG. 7( a) and/or 7(b). Theseconductor segments are often referred to as “hairpins” because of theirshape. The U-shaped conductor segments may be inserted into the slotsfrom one side of the lamination stack, legs first, with each legpositioned in a different slot. The leg ends of the hairpins extendingthrough the slots (i.e., the open ends of the hairpins) are then bent toa desired configuration, as shown in FIG. 7( c), so each respective legend may be joined to a different leg end according to the connectionrequirements of the windings. Finally the corresponding rectangularwires are connected into 3-phase or multi-phase AC windings.

This “hairpin” winding technology is already in application in manyproducts such as Remy International, Inc.'s 50DN alternator (since the1960's), shown in FIG. 3( b). The configuration of the windings shown inFIG. 3( b) (i.e., double layer windings with one strand per conductor)leads to high conductor thickness, which (among other reasons) causessevere skin effect and low efficiency (less than 50%).

To lower the skin effect while maintaining the high slot-fill-ratio ofrectangular wire AC windings, each conductor could be composed of aplurality of thin rectangular wires or “strands”, as shown in FIG. 4(a). Like the above-described hairpin winding process, the conductor withmulti-strands could be transitioned at the end-turn, shaped intoU-shapes and inserted into the slots from one side of the laminationstack. After all U-shape coils are inserted into slots, the opensegments of the U-coils would be reshaped to the required shapes andconnected into phase windings. One prototype of this technology is shownin FIG. 4( b). However, because of limitations of the number of slotsand the available end-turn space, the practical application of FIGS. 4(a) and 4(b) is wave windings with one turn per coil since connectingwires between poles at lap windings could spoil the end-turn space.Therefore, this technology can be only used for low voltage AC windingslike the FIG. 4( b) prototype. Furthermore, another manufacturing issueexists because of the difficulty in twisting multi-strand rectangularwires.

Another solution to the above-referenced problems involves shaping eachstrand into a single turn coil and then two U-shape coils are insertedinto the slots, as shown in FIG. 5( a), instead of combining two strandsin one conductor as shown in FIG. 4( a). Following the same procedure ashairpin winding manufacturing in FIG. 3( b), an automotive alternatorwhich uses two sets of overlapping windings (i.e., one on top of theother) being connected with two separate rectifiers in parallel can becreated. However, besides requiring two bridges, the overlapped windingsincrease the difficulty in manufacturing and the possibility forshort-circuits. Furthermore, added end-turn length is required foroverlapped windings (i.e., the size of the winding head is increased).This added length is undesirable in modern vehicles, such as the HEVwhere machine space is of much concern. In addition, the repair ofoverlapped windings is very difficult if not impossible, as one set ofwindings completely encompasses the other set of windings.

SUMMARY

An electric machine having multi-set rectangular copper hairpin windingscomprises a stator having a plurality of partially closed stator slots.A first winding set is positioned in the stator slots. The first windingset comprises a first plurality of hairpins forming a first layer ofconductors in the stator slots and a second layer of conductors in thestator slots. The first plurality of hairpins each include two legs,each leg having a leg end, and each leg end bent to a desiredconfiguration to form adjacent leg ends between the first layer ofconductors and the second layer of conductors. A second winding set isalso positioned in the stator slots. The second winding set comprises asecond plurality of hairpins forming a third layer of conductors in thestator slots and a fourth layer of conductors in the stator slots. Thesecond plurality of hairpins each include two legs, each leg having aleg end, and each leg end bent to a desired configuration to formadjacent leg ends between (i) the second layer of conductors and thethird layer of conductors and (ii) the third layer of conductors and thefourth layer of conductors. The second winding set is joined to thefirst winding set by connecting at least one or two of the adjacent legends per phase between the second layer of conductors and the thirdlayer of conductors. Accordingly, the winding sets may be easilyconnected, such as through the use of an automatic hairpin windingconnection machine.

The windings formed in the stator slots also provide for improved skineffects in the electric machine. According to a first embodiment,conductor layers in alternate slots alternate between different phases.The conductor layers in the remaining slots are all of the same phase.Hairpins having unequal length legs are used to implement the firstembodiment. According to a second embodiment, conductor layers inalternate slots include one phase for the first winding set and anotherphase for the second winding set. The conductor layers in the remainingslots are all of the same phase. Hairpins having equal length legs areused to implement the second embodiment.

To manufacture an electric machine having multi-set rectangular copperhairpin windings, rectangular copper wires are cut to required lengthsand pre-shaped as “U-shaped” hairpins with the appropriate coilpitch/span. The U-shaped hairpin conductors are inserted intorectangular slots of the lamination stack of the electric machine. Afterinserting the hairpins of one complete winding set, the open end-turnsare bent in preparation for a wave-winding connection. The sameprocedure is repeated until all winding sets are installed. Finally, theconnecting points between “hairpins” are welded into wave windings withone or two parallel paths per phase, depending on the winding design.

Accordingly, multi-set rectangular copper hairpin windings are providedthat increase the slot-fill-ratio up to 75% or higher in the electricmachine with semi-closed or closed slots. This is especially useful forhybrid vehicle applications. Combining semi-closed slots with lowrectangular wire thickness (due to introducing multi-sets windings)reduces the skin effect, allowing high efficiency operation even at highspeed. Furthermore, the multi-set rectangular hairpin windings providean electric machine having side-by-side windings that provide for lowmanufacturing costs and low maintenance costs. The side-by-side windingsets also provide for winding arrangements that further reduce skineffects. This technology can be extended and used for other ACmulti-phase (e.g., three phase) electric machines.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1( a) and 1(b) show a comparison of rectangular wires (FIG. 1( a))and round wires (FIG. 1( b)) in the slot of an electric machine;

FIG. 2 shows transitioned winding bars as used in the slots of largeelectric machines;

FIG. 3( a) shows the twisting transition of an end winding used in somelarge electric machines;

FIG. 3( b) shows the stator of an electric machine using “hairpin”winding technology with double layer windings and one strand perconductor/layer;

FIG. 4( a) shows a multi-strand hairpin winding used in some electricmachines;

FIG. 4( b) shows a prototype electric machine using the winding of FIG.4( a);

FIG. 5( a) shows an overlapping hairpin winding arrangement having twosets of windings;

FIG. 5( b) shows a stator wound with the overlapping winding arrangementof FIG. 5( a);

FIGS. 6( a), 6(b) and 6(c) show the skin effect sequence from high (FIG.6( a)) to low (FIG. 6( c)), depending on conductor arrangements in aslot.

FIGS. 7( a), 7(b) and 7(c) show the progression of a single element of arectangular copper hairpin winding from its shape before insertion intoa slot (FIG. 7( a)) to its shape after insertion into a slot (FIG. 7(c));

FIG. 8( a) shows a perspective view of a stator wound with rectangularcopper hairpin windings comprised of two winding sets as viewed from theinsertion end of the stator;

FIG. 8( b) shows a perspective view of the stator of FIG. 8( a) asviewed from the connection end of the stator;

FIG. 9 shows the end-turn connections of one winding phase for a doublewinding set having hairpin legs of unequal length;

FIG. 10 shows a distributed graph of two sets of rectangular copperhairpin windings for the double winding set of FIG. 9;

FIG. 11 shows the end-turn connections of one winding phase for a doublewinding set having hairpin legs of equal lengths;

FIG. 12 shows a distributed graph of two sets of rectangular copperhairpin windings for the double winding set of FIG. 11;

FIG. 13 shows the hairpin connection points and phase terminalarrangements of FIGS. 11 and 12;

FIG. 14 shows a comparison of generating characteristics betweenelectric machines using multi-set rectangular copper hairpin windingsand an electric machine using traditional round wire windings;

FIG. 15 shows a comparison of AC phase resistances between electricmachines using multi-set rectangular copper hairpin windings and anelectric machine using traditional round wire windings;

FIG. 16 shows a comparison of motoring efficiencies between electricmachines using multi-set rectangular copper hairpin windings and anelectric machine using traditional round wire windings;

FIG. 17 shows an enlarged view of adjacent leg ends as viewed from theconnection end of the stator;

FIG. 18( a) shows an enlarged perspective view of the U-shaped end turnsof side-by-side winding sets as viewed from the insertion end of thestator;

FIG. 18( b) shows an enlarged top view of the U-shaped end turns of FIG.18( a);

FIGS. 19( a)–19(c) show a winding schematic for an electric machinehaving multi-set rectangular copper hairpin windings with legs ofunequal lengths; and

FIGS. 20( a)–20(c) show a winding schematic for an electric machinehaving multi-set rectangular copper hairpin windings with legs of equallengths.

DESCRIPTION

Winding Overview

With reference to FIGS. 8( a) and 8(b) an electric machine is shownhaving multi-set rectangular hairpin windings formed thereon. Theelectric machine comprises a stator having a plurality of partiallyclosed slots. A plurality of conductor segments are positioned withinthe slots of the stator and form a plurality of winding sets upon thestator. Each of the winding sets includes a phase A winding, a phase Bwinding, and a phase C winding. The winding sets are each adjacent toeach other upon the stator, with one of the winding sets forming aninner winding set 50 and another of the winding sets forming an outerwinding set 52.

Each winding set is comprised of a plurality of conductor segments, alsoreferred to herein as “hairpins,” positioned within the slots of thestator. With reference to FIG. 7, each of the plurality of hairpins 30includes a “U” shaped end turn 32 and two legs 34. Each of the pluralityof hairpins has a rectangular cross-sectional shape. The legs of thehairpins are positioned in the slots of the stator with each leg of thehairpin in a different stator slot such that the U-shaped end-turn ofthe hairpin extends over several stator slots (e.g., each U-shapedend-turn may extend six stator slots). Each hairpin inserted into astator slot is staggered or “interleaved” with respect to adjacenthairpins. When a hairpin is fully inserted into the slots of the stator,the U-shaped end turn 32 will extend from one end of the stator (i.e.,the insertion end), and the legs will extend from the opposite end ofthe stator (i.e., the connection end). Any given stator slot willinclude a number of hairpin legs (e.g., 4), and each hairpin leg isreferred to as a “layer” within the stator slot. FIG. 6( a) shows across-section of a stator slot having four layers of conductors (i.e.,legs) carrying the same phase current in the stator slot. The layers arereferenced herein as the innermost layer (i.e., the layer closest to theneck of the slot) being layer 1 and the outermost layer (i.e., the layerfurthest from the neck of the slot) being layer 4. Insulation 38 isincluded on the portion of each leg situated within a stator slot toprevent electrical connection between the legs in different layers ofthe same stator slot. The insulation 38 may alternatively take the formof slot insulation provided inside each slot and between conductors.

The portions of the hairpin legs extending from the stator slots arebent in a desired configuration. To reduce winding height the legs onalternating layers are bent in opposite directions (e.g., the legs onlayer one are bent counter-clockwise in the same direction and the legson layer two are bent in the opposite direction, clockwise). The numberof stator slots that each leg is bent is determined upon the design ofthe electric machine (e.g., each leg may be bent three slots so that thehairpin extends a total of twelve slots from end-to-end in wavewindings, if the end turn of each side extends six slots). FIG. 17 showsa close-up view of a typical arrangement of the ends of the hairpin legsextending from the stator slots. As shown in FIG. 17, the legs are bentsuch that each leg end 36 is positioned adjacent to another leg end.This allows an electrical connection be easily established between eachadjacent hairpin leg. In particular, once all hairpin legs are insertedinto the stator and bent, an automated connection device is used to weldlegs together. For example, adjacent legs 36(a) and 36(b) may be weldedtogether and adjacent legs 36(c) and 36(d) may be welded together.Similar welds would be made for other adjacent legs around the stator.The automatic connection device may also provide insulation that coversthe ends of the legs to prevent electrical shorts between two nearbylegs that are not intended to be connected. The term “adjacent leg ends”is used herein to refer to two hairpin leg ends from different hairpinsthat are immediately adjacent to one another (such as leg ends 36(a) and36(b) and leg ends 36(c) and 36(d) of FIG. 17) when the legs are bentinto the proper arrangement in the stator core. Non-adjacent leg endsare any leg ends that are not adjacent leg ends (e.g., leg endsdiagonally opposed to each other such as leg ends 37(c) and 36(d) ofFIG. 17, and leg ends removed by several positions such as leg ends36(d) and 39(d) of FIG. 17). This portion of the stator windingextending above the stator core forms the winding head 44.

On the opposite side of the stator from the hairpin leg ends, theU-shaped end turns of the hairpins extend from the stator slots. FIG. 18shows a close-up view of the U-shaped end turns of the hairpinsextending from the stator slots. As shown in FIG. 18, the U-shaped endturns form (i) a inner winding set 50 comprising a first group ofend-turns, and (ii) an outer winding set 52 comprising a second group ofend-turns positioned on the exterior of the stator slots. The windingsets do not overlap each other (i.e., the U-shaped end turns fromdifferent winding sets do not overlap each other), but instead thewinding sets are “side-by-side” (i.e., concentrically positioned next toeach other such that the U-shaped end turns are non-overlapping). Thenon-overlapping U-shaped end turns of the inner winding set and theouter winding set allow for the winding schematics shown in FIGS. 19 and20 to be realized. As described in more detail below, each of thesewinding schematics provides for electric machine windings having highslot-fill-ratio, low skin effects, low manufacturing costs and lowmaintenance costs.

Winding Design to Account for Skin Effect

As described above, two or more double layer winding sets are embeddedside-by-side in armature slots (creating at least one inner and oneouter winding set). The winding coils are made with rectangular copperhairpin conductors. The number of winding sets depends on the requiredthickness of the rectangular conductor to meet the needs of systemvoltage and low skin effect. A conservative rule-of-thumb is todetermine the thickness, h, of each conductor in a slot is:

$\begin{matrix}{{h = \frac{1.32}{\sqrt{m}}}{d = {\frac{1.32}{\sqrt{m}}\sqrt{\frac{b_{s}}{b_{c}}\frac{\rho}{\pi\; f\;\mu}}}}} & \lbrack {{equation}\mspace{14mu}(2)} \rbrack\end{matrix}$where m is the number of conductors in the direction of slot height(i.e., distance from outer periphery of slot to inner periphery of slotwhere opening is fount); d is the penetrated depth of electromagneticwave, given in equation (1); and the other variables and constants arethe same as provided above for equation (1). Considering manufacturingcost and complexity, 2 to 3 sets of windings (with a maximum of 4winding sets, in spite of a theoretically unlimited number of windingsets) are more practical in AC winding manufacturing.

It has been determined that conductors in a slot carrying differentphase currents will produce lower skin effects in double layer windingsthan those conductors in a slot all carrying the same phase currents.FIG. 6 shows a number of different conductor arrangement/phase currentconfigurations for a slot carrying two winding sets. The sequence ofskin effects from high to low order in FIG. 6 is from FIG. 6( a) to FIG.6( c). In other words, the arrangement shown in FIG. 6( a) will producehigher skin effects than the arrangement of FIG. 6( b), and thearrangement of FIG. 6( b) will produce higher skin effects than FIG. 6(c). Thus, it is advantageous to produce a winding configuration where asmany of the slots as possible resemble the arrangement of FIG. 6( b) orFIG. 6( c), with FIG. 6( c) being the most advantageous arrangement.

Based on FIG. 6, the coil pitch, Y₁, in the three phase AC windingswould be better within (1/3)τ<Y₁≦(2/3)τ, where τ is the pole pitch inslots. Unfortunately, the copper utilization of AC windings will be verylow at low coil pitch such as Y₁<(2/3)τ. For practicality, the coilpitch of (2/3)τ<Y₁≦1 is used in most high efficient electric machines.Likewise, as shown in FIGS. 19 and 20, a coil pitch of Y₁>(2/3)τ is usedherein to describe the exemplary winding configurations that utilizemulti-set rectangular copper hairpin windings while providing for lowerskin effect.

Procedures of Winding Manufacturing

The following procedural steps are used in the manufacturing of thewindings shown in FIGS. 19 and 20, that provide multi-set copperrectangular hairpin windings with lower skin effects.

(A) At first, the rectangular copper wire is cut into elements. Itshould be noticed that the length of elements of the inner winding setis slightly different from the length of the outer winding set elementsdue to different diameters of winding set locations. There are also twoshorter pitch elements (one slot shorter, compared to the others) withper phase per winding set if the windings are connected into wavewindings.

(B) Based on pitch requirements, the rectangular wires are bent intoU-shapes, as shown in FIG. 7( a). Because the thickness of each wire inthe slot height direction is reduced by increasing the number ofwindings sets, the twisted end-turn 32 in FIG. 7( a) can be replaced bya flat bent end-turn, which can reduce the manufacturing complexity. Infact, as described below, the length of U-shape hairpin legs can beeither equal or unequal, based on practical requirements.

(C) The U-shape rectangular wire is insulated by rectangular insulationtube or bounding insulation, as shown in FIG. 7( b). However, the tubeinsulation can be eliminated if traditional slot insulation is used(e.g., slot liners and/or existing wire enamel that provides the properinsulation for the electric machine's voltage rating).

(D) All conductor elements of one complete winding set are inserted intothe stator slots. Generally, the inner set or top set (i.e., the set attop of slot) is inserted first, although other sequences are possible.

(E) The legs of all the U-shape hairpins are bent into “frog-shape” withan automatic bending machine. Typically, the legs of one layer are bentin the clockwise direction and the legs of the adjacent layer are bentin the counterclockwise direction. A bent hairpin element removed fromthe slots is shown in FIG. 7( c).

(F) Next, procedures (D) and (E) above are repeated for the remainder ofsets until the winding sets are all positioned upon the stator. Ahairpin winding with double sets is shown in FIG. 8.

(G) Finally, connections are made between the leg ends to complete thewinding end turns and make the connections according to the windingschematic. Most of the required connections are between adjacent legends. However, a few of the connections require jumpers.

End-Turn Connections

End-turns are used for connecting the effective segments of elements inslots. To reduce resistance losses and leakage, end-turns are requiredto be kept as short as possible. The available mounting space on thevehicle also limits the overall length of the electric machine so theshorter end-turns are preferred. Compared to a conductor composed ofstrands, such as that shown in FIG. 4, the multi-set rectangular hairpinwinding is beneficial in making the end-turn shorter. An additionaladvantage is heat expulsion through the stator stack (e.g., enclosedair-cooling, indirect liquid cooling, etc.). Conversely, end-turns areused to expel heat in the winding if direct oil cooling or opencirculating air cooling system is employed. The end-turns must haveenough surface area and clearance between conductors for desired heatrejection. A reasonable length of end-turn is chosen according toelectric and thermal requirements as well as physical limitations on endturn length.

Unlike the end-turn length, the jumpers or connections between poles,winding sets, phases, paths, etc., do not contribute much to machinecooling so the length is kept as short as possible. To reduce the numberof connections like these, wave style winding is better than lap style.The following end-turn connection methods provide significantadvantages.

(i) Rectangular Hairpins with Unequal Legs

According to AC winding theory, in order to reduce MMF harmonics withlow orders (5^(th) and 7^(th) mainly), the “first pitch” of the windings(i.e., Y₁, the number of slots between legs connected by the U-shapedend turn, the “winding pitch”) should be as near (5/6)τ as possible(where τ is pole pitch in slots). This causes the pitch of connectionsbetween winding sets to be near (4/3)τ while the “second pitch” (i.e.,Y₂, the second pitch of windings, and particularly the number of slotsbetween conductors that are connected at their leg ends, the “connectionpitch”) within a winding set is near (7/6)τ. To accomplish the abovepitch arrangement using hairpins having legs of equal length, theconnections between winding sets have to be extended in an axialdirection, thereby increasing the overall length of the machine. Inother words, the connections between winding sets require connectionbetween non-adjacent leg ends, and such connections require jumperingthat increases the height of the winding head. However, the use ofhairpins with legs of unequal length can avoid the need to extend theconnections between winding sets in the axial direction.

As an example of the above, consider a three phase, two-set AC windingwith 10 poles and 60 slots, such as that shown in FIG. 19. A detailedlook at the end-turn jumpers and some connections that are required forphase A of this arrangement are shown in FIG. 9. In this example, thelayers are defined as the 1^(st) through 4^(th) from the top to thebottom of a slot. The 1^(st) & 2^(nd) layers consist of winding set 1while the 3^(rd) & 4^(th) layers consist of winding set 2. The linessuperimposed over the conductor layers show the connections betweenhairpin leg ends on the connection end of the stator. The clearrectangles represent phase A, the darkened rectangles represent phase B,and the striped rectangles represent phase C. Of course, the conductorlayers are also connected by U-shaped end turns at the insertion end ofthe stator, but these connections are not provided for clarity in FIG.9. The first pitch Y₁ of the windings (hairpin pitch) is 5 (this is thenumber of slots that the U-shaped end turns span). For example, startingat layer 4 in slot 4 and following dotted reference line 100 to layer 3of slot 9, it can be seen that this connection extends 5 slots. Thesecond pitch, Y₂, of the windings (hairpin connection within a set) is7. For example, starting at layer 3 in slot 9 and following referenceline 102 to layer 4 of slot 16, it can be seen that this connectionextends 7 slots. It should also be noted that there exist 2 connectionsper set per phase that have a shorter Y₂ by one slot (e.g., starting atlayer 3 in slot 57 and ending at layer 4 in slot 3, as represented byreference line 104, the second winding pitch is only 6 instead of 7).The connection pitch between winding sets 1 & 2 is 8 (e.g., as shown byreference line 108, starting at layer 3 in slot 2 and ending at layer 2in slot 10).

To connect all rectangular hairpins in one level of axial length, theends of hairpin legs to be connected between winding sets have to bealigned with each other (i.e., adjacent leg ends). To accomplishadjacent leg ends according to the winding schematic of FIGS. 9 and 19,hairpin legs with unequal length are required. Accordingly, all legs inthe 1^(st) layer in FIGS. 9 and 19 (i.e., the innermost layer withreference to FIG. 8( b)) are bent across 3 slots counter-clockwise whilelegs at the 2^(nd) layer (except shorter Y₂ between hairpins) are bentacross 4 slots clockwise. For winding set 2, legs at layer 3 (exceptshorter Y₂ between hairpins) are bent across 4 slots counterclockwise,while all legs at layer 4 are bent 3 slots clockwise. In this way, allthe end-turns connections to be made as shown in FIG. 19 are betweenadjacent leg ends (with the exception of the one jumper connectionbetween F_(A3) and F_(A4)), including the connections between windingsets from layer 2 to layer 3 (i.e., the connection between F_(A2) andS_(A4), noted by reference line 106, and the connection between F_(A1)and S_(A3), noted by reference line 108). Because the connectionsbetween adjacent leg ends may be made by an automatic connectionmachine, and jumpers or other extended connections are not required, therequired connections between the hairpins may be made without raisingoverall length of the electric machine.

The bending and connecting is shown as a distributed graph in FIG. 10,which shows the phase A winding schematic for slots 52–16. As notedabove, connecting F_(A2) with S_(A4) in FIG. 10 corresponds to theconnection between winding sets starting at layer 3 in slot 56 andending at layer 2 in slot 4. Connecting F_(A1) with S_(A3) in FIG. 10corresponds to the connection between winding sets starting at layer 3in slot 2 and ending at layer 2 in slot 10. To complete the winding set,the same procedure is repeated for connecting hairpins in phases B and Cas in phase A. Finally, the two sets of rectangular hairpin windings areconnected into one path per phase through connecting F_(A4) and F_(A3)and Y-connection of three phases. The winding arrangement shown in FIG.19 not only provides the advantages of reduced harmonics associated withshort pitch winding, but also provides for connection betweenside-by-side winding sets using adjacent leg ends. By providing for easyconnection between hairpins, including easy connection between windingsets through adjacent leg ends, the overall length of the electricmachine does not need to be increased. In addition, only three jumpersare required for the complete winding set shown in FIG. 19.

Another significant advantage of the winding arrangement shown in FIG.19 (i.e., hairpin connections using hairpins with unequal legs) is anumber of slots having different phase currents. As discussedpreviously, low skin effect is realized in slots with different phasecurrents due to the arrangement of the phase conductors. For instance,the conductors carrying A, B, A, B phase currents in slot 8 of FIG. 9reduce the skin effects as explained above with reference to FIG. 6( c).As best shown in FIG. 9, the winding arrangement of FIG. 19 providesreduced skin effects, as the conductor arrangement in all even numberedslots is that of FIG. 6( c). In particular, the first and second layers(i.e., the conductors included in the first winding set) in all of theeven numbered slots carry different phase currents and the third andfourth layers (i.e., the conductors included in the second winding set)in all the even numbered slots also carry different phase currents, withthe pattern of phase currents in layers one and two being the same asthe pattern of phase currents in layers three and four. At the sametime, all of the layers in the odd numbered slots carry the same phasecurrent. (The terms “even numbered slots” and “odd numbered slots” areused herein to reference alternating slots. Choice of slot numbering isa design choice, and the terms “even numbered slots” and “odd numberedslots” are not intended to serve any limiting purpose other than toreference alternating slots. Accordingly, the conductor arrangement ineach slot of the winding schematic shown in FIG. 19 alternates betweenthe configuration shown in FIG. 6( a) and the configuration shown inFIG. 6( c). The improved skin effect in the even numbered slotsminimizes skin effect in the windings, as described previously withrespect to FIG. 6( c).

(ii) Hairpins with Equal Legs for Even Number of Winding Sets

If the number of winding sets is even, such as 2 or 4 etc. (andespecially for 2 sets), an alternative embodiment of the invention canbe implemented where the short pitch for reduction of harmonics isperformed by shifting the proper number of slots between sets of thefull pitch windings. This gives an opportunity to build hairpins withequal legs while the harmonics are still depressed. In this embodiment,all rectangular hairpins are formed with equal length legs and fullpitches within each winding set, except 2 hairpins/coils per phase areformed with short pitch (i.e., τ−1) in each winding set due towave-wound features. The shift of alignment position between windingsets is taken about (1/6)τ to suppress the 5^(th) and 7^(th) harmonics,or (1/ν)τ to eliminate the ν^(th) harmonic.

As an example, again consider a three phase, two-set AC windings with 10poles and 60 slots, such as that shown in FIG. 20. A detailed look atthe end-turn jumpers and some connections that are required for phase Aof this arrangement is shown in FIGS. 11 and 12. In this example, thelayers are defined as the 1^(st) through 4^(th) from the top to thebottom of a slot. The 1^(st) & 2^(nd) layers consist of winding set 1while the 3^(rd) & 4^(th) layers consist of winding set 2. All hairpinshave equal length legs (except for the legs of two hairpins per phaseper set, as mentioned above) and each leg is bent three slots. Thesecond pitch Y₂ (connection pitch within a set) is six slots as shownstarting with layer 1 of slot 9 and following reference number 114 tolayer 2 of slot 15. The first pitch (hairpin pitch) is also 6 slots. Itshould also be noted that there exist 2 connections per phase per setthat have a shorter Y₂ by one slot (e.g., starting at layer 3 in slot 58and ending at layer 4 in slot 3, as represented by reference line 116,the second winding pitch is only 5 instead of 6). The connection pitchbetween winding sets 1 & 2 is 6 (e.g., as shown by reference line 110,starting at layer 3 in slot 57 and ending at layer 2 in slot 3).Connections between F_(A2) & S_(A4) 110 and F_(A1) & S_(A3) 112 in FIGS.12 and 20 are simply made because the connection is made betweenadjacent leg ends between the second and third layer. The series pathunder north poles and the path under south poles are connected into oneor two paths based on design. In this example, connecting F_(A4) &F_(A3) using jumpers yields one series path per phase.

Comparing FIGS. 11 and 12 with FIGS. 9 and 10, the combination of twowinding sets with full pitch hairpin coils in FIGS. 11 and 12 shows thesame winding factors for both fundamental and harmonics as thecombination of two winding sets with short pitch hairpin coils in FIGS.9 and 10. With respect to either MMF or main EMF, after shifting one ormore slots between sets, the full pitch hairpin windings with equal legsis nearly equivalent to the short pitch hairpin windings with unequallegs. The hairpins with equal legs have the shorter end-turn length thanhairpins with unequal legs. It should be noticed, however, that thisadvantage is a trade-off with slightly higher skin effect in slotscontaining different phase current carriers since the phase conductorcombination for the hairpins with equal legs, in slots with differentphase current carriers, belongs to the type shown in FIG. 6( b). Inparticular, the first two layers (i.e., the conductors included in thefirst winding set) in all of the even numbered slots carry a first phasecurrent that is different than a second phase current carried in layersthree and four (i.e., the conductors included in the second windingset). At the same time, all of the layers in the odd numbered slotscarry the same phase current. Accordingly, the conductor arrangementalternates between the configuration shown in FIG. 6( a) and theconfiguration shown in FIG. 6( b). The improved skin effect in the evennumbered slots is nearly equal to that realized in the above embodimenthaving unequal leg lengths.

Because small and mid-sized electric machines typically use semi-closedslots, hairpin windings are used to accomplish the above-describedwinding configurations (there are also benefits to semi-closed slots aspreviously mentioned). For simplicity, only a portion of the phase Awinding set is shown in FIGS. 9–12, but the complete winding arrangementfor phases A, B and C is provided in FIGS. 19 and 20.

Utilizing a combination of shifting angle/slots between pairs of windingsets can create various equivalent short pitches. As an example, 4-setsof full pitch windings can be broken into two groups of two-setwindings. If the shift angle between the two-sets in the first group is(1/9)τ while the shift angle between two-sets in the second group is(2/9)τ, the equivalent winding pitch of the 4-set windings is (7.5/9)τ,which provides suppression of both the 5^(th) and 7^(th) harmonics,which is better than using a winding pitch of (7/9)τ or (8/9)τ. Thismethod provides much more flexibility in choosing winding pitches, whichcannot be done in traditional double layer windings.

The above descriptions with reference to FIGS. 9–12 and 19 and 20 haveincluded only two-sets of rectangular copper hairpin windings in anattempt to simplify the description. However, alternative embodimentsmay certainly include more than two-sets of windings.

(iii) Separation of Hairpin Connections with Phase Terminal Connections

Conventionally, the phase terminal connections and the hairpinconnections are at the same end of armature stack, such as in FIG. 3( b)and FIG. 8( b). Those arrangements do not affect the manufacturingprocedures in making manual welded connections. However, it is difficultto weld all connection points in automatic welding by mechanical armsbecause the longer phase terminal wires in the way. Thus it will behelpful to separate the hairpin connections with phase terminalconnections, i.e., the hairpin connections are arranged on one end ofthe armature stack and all phase terminal connections are located on theother end of the armature stack. As a result, all connection points areuniformly and neatly placed at the same axial level on the hairpinconnection end of the armature, which makes the welding process easilyperformed by mechanical arms automatically. At the same time, theconnection points are not aligned over each other in the radialdirection on the other end of the armature so the potential shortcircuits between welding points are avoided. Unlike the phase terminalscoming out between hairpins as shown in FIG. 5( b), the phase terminalscome out either from the inner diameter or the outer diameter of overallend-turns.

To clearly show the location of hairpin connections and phase terminals,the windings in the examples of FIGS. 11 and 12 are redrawn in FIG. 13,with all phases shown. The rectangular copper hairpins are inserted intothe slot from one end of the armature while the connection pointsconsisting of bent rectangular hairpin legs are located at top of thedistributed winding drawing of each set in FIG. 13. The phase terminalsand connections of the two-sets (4 layers of coil sides of each slot) inthe rectangular copper hairpin windings are described as follows:

-   Phase A: (I) Connect F_(A1) of layer 3 and S_(A3) of layer 2    -   (II) Connect F_(A2) of layer 3 and S_(A4) of layer 2-   Phase B: (I) Connect F_(B1) of layer 3 and S_(B3) of layer 2    -   (II) Connect F_(B2) of layer 3 and S_(B4) of layer 2-   Phase C: (I) Connect F_(C1) of layer 3 and S_(C3) of layer 2    -   (II) Connect F_(C2) of layer 3 and S_(C4) of layer 2

In this example, three phase windings are connected in one series pathper phase with an Y-connection of the three phases. F_(A3) & F_(A4) ofphase A, F_(B3) & F_(B4) of phase B and F_(C3) & F_(C4) of phase C areconnected in series, respectively. S_(A1), S_(B2) and S_(C2) areconnected to the neutral. S_(A2), S_(B1) and S_(C1) are left for threephase terminals A, B and C.

Example Simulation Results

The following data is an example simulation to show the improvement onperformance and machine size with the disclosed winding technology.

A three phase induction machine (Machine I) is provided as follows:2P=10 poles; stator/rotor slots Z₁/Z₂=90/112; q=3 slots per phase perpole; coil pitch Y₁=8 slots; N_(c)=13 turns per coil; a=10 parallelpaths; wire size 2×AWG^(#)18½; slot-fill-ratio=42%; double layer lagwindings; Y-connection; stator ID/OD=293.52/369.56 mm; stator lengthL=127.5 mm, end turn length (two sides) Le=58+34=92 mm.

A rectangular copper hairpin winding (Machine II) is provided asfollows: windings S=2 sets, 2p=10 poles; stator/rotor slots Z₁/Z₂=60/64;q=2 slots per phase per pole; coil pitch Y₁=5 slots; N_(c)=1 turns percoil; a=1 parallel paths; wire size W6.7 mm×H3.35 mm;slot-fill-ratio=67%; double layer wave windings each set; Y-connection;stator ID/OD=293.52/369.56 mm; stator length L=127.5 mm; end turn length(two sides) Le=40+32=72 mm.

After changing the stator windings from round wire to two-setrectangular hairpin windings, the output power of the machine increasesat low speed range under the same limitation of AC current or the sameVolt-Ampere (VA) capability of the power electronic converter, shown inFIG. 14. If the thermal load or total loss of the machine is used ascriterion, the difference of output power between the patented machineand conventional machine with round wires will increase further becauseof high slot-fill-ratio and low AC phase resistance in the low speedrange. The improvement on power generation at low speed is veryattractive for HEV's.

As discussed previously, the provided embodiments of the multi-setrectangular copper hairpin windings addresses the skin effect, orincrease of AC resistances in the electric machine if the conductorheight in slots are not small enough. The AC resistances are calculatedunder the worst situation (i.e., open slots, as the practical ACresistance should be lower in windings with semi-closed slots). For twowinding sets (4 layers of rectangular conductor with the thickness ofabout 3.5 mm), FIG. 15 shows that the AC phase resistance in thepatented winding is lower than that in traditional round wire windingsuntil approximately 3500 rpm. In fact, the electric machine generallyoperates below 3500 rpm, and seldom runs near the engine's red linespeed of 5500 rpm for direct drive configuration. Increasing the numberof winding sets will lower the skin effect and consequently the ACresistance. Combining manufacturing cost with machine performance,however, two-set rectangular copper hairpin windings already fit thisapplication very well. The efficiency curve at full-load and motoringoperation of the patented machine is given in FIG. 16, in which the skineffects are included. The performance curves show a big improvement atlow speed while slightly sacrificing performance in the red-line speedrange.

The winding design disclosed herein demonstrates improvements for directsurface oil cooling systems. No additional end-turn insulation isrequired on the windings because of the existence of space (clearance)between end-turn conductors. As a result, thermal transfer capabilityand manufacturing cost are improved. Furthermore, the side-by-sidewinding arrangement provides for more oil flow over the end turns thanwith overlapping coil wound designs.

In addition to the above, the winding design disclosed herein providesfor reduced overall length of the electric machine. In particular, theend-turn length (and the overall length of the machine) is reduced byabout 20 mm when compared to overlapping winding designs. This isaccomplished because of short end-turns and the absence of an AC bus atthe end-turn area.

In addition to the above advantages, the winding design disclosed hereinprovides for an electric machine having a high slot-fill-ratio (e.g., upto 75% ratio of area of bare wires to total slot cross section area),high efficiency at low rpm, lower manufacturing costs, a large end-turnheat rejection area, high heat conductivity in the slots, and ease ofwinding maintenance and repair (as compared to overlapping windingarrangements).

The electric machine having multi-set hairpin windings as describedherein is particularly applicable for use with hybrid vehicles in theautomobile and truck industries. However, the hairpin wound electricmachine having multi-set hairpin windings described herein may also beused in any three-phase (or any phase number) AC electric machine (bothmotor and generator) required to operate efficiently over a wide speedrange. As described above, the electric machine provides highslot-fill-ratio (up to 75% bare copper to slot area ratio) and reducesthe negative skin effects of AC windings, leading to higher efficiencyof the electric machine and lower fuel consumption (saving energy) forenvironmentally friendly hybrid electric vehicles or pure electricvehicles.

Although the present invention has been described in considerable detailwith reference to certain preferred versions thereof, other versions arepossible. For example, the wave winding connection described abovereduces jumper-wires between poles, so the coil turns per phase can notbe chosen flexibly and the parallel paths per phase can be only one ortwo in order to avoid the use of an AC bus at end-turns. However, toincrease the flexibility in selection of the winding series turns perphase, the slot number and the number of winding sets can be changed.For example, the number of stator slots can be 60, 90 and 120 for 10pole three phase machine windings, and the winding sets can be chosen as2, 3 or more. Some fractional slot windings can be introduced to furtherincrease the flexibility. These provide more choices for winding turns.At the same time, changing lamination stack length also can adapt thedesign to a wide range of voltage at a given number of turns per phase.This becomes possible because a shorter end-turn in the inventedwindings provides more flexibility in selecting stack length to keep theoverall length of machine within available space. Furthermore, changingpole number in machine design can also adapt to some available windingturns provided by the disclosed winding technology. In addition, themanufacturing cost increase due to the number of welding points can bereduced through the introduction of an automatic welding process sincethe adjacent end-turns provide potential for an automatic productionline. Therefore, the spirit and scope of the appended claims should notbe limited to the description of the preferred versions containedherein.

1. An electric machine comprising: a stator having a substantiallycylindrical interior, said stator comprising a plurality of statorslots; a first plurality of hairpin conductors positioned in said statorslots in a short pitch arrangement to form a first winding set, saidfirst plurality of hairpin conductors each including an end turn and twolegs of unequal length, said legs of unequal length of each of saidfirst plurality of hairpin conductors bent outward to generally followthe circumference of said stator, wherein the longer of said legs ofunequal length of each of said first plurality of hairpin conductors isbent in a first circumferential direction and the shorter of said legsof unequal length of each of said first plurality of hairpin conductorsis bent in a second circumferential direction; a second plurality ofhairpin conductors positioned in said stator slots in a short pitcharrangement to form a second winding set, said second winding set beingsubstantially concentric with said first winding set, said secondplurality of hairpin conductors each including an end turn and two legsof unequal length, said legs of unequal length of each of said secondplurality of hairpin conductors bent outward to generally follow thecircumference of said stator, wherein the shorter of said legs ofunequal length of each of said first plurality of hairpin conductors isbent in said first circumferential direction and the longer of said legsof unequal length of each of said second plurality of hairpin conductorsis bent in said second circumferential direction; and at least oneelectrical connection between said first winding set and said secondwinding set, said at least one electrical connection made by joining atleast one leg of said first plurality of hairpin conductors to at leastone adjacent leg of said second plurality of hairpin conductors.
 2. Theelectric machine of claim 1, further comprising: at least one otherplurality of hairpin conductors positioned in said stator slots in ashort pitch arrangement to form at least one other winding set, said atleast one other winding set being substantially concentric with saidfirst winding set.
 3. The electric machine of claim 1, furthercomprising: hairpin conductor insulation, said hairpin conductorinsulation applied to at least one of said first plurality of hairpinconductors before said first plurality of hairpin conductors arepositioned in said stator slots.
 4. The electric machine of claim 1,wherein said first plurality of hairpin conductors and said secondplurality of hairpin conductors are positioned in said stator slots suchthat said end turns protrude from a first axial end of said stator andsaid legs protrude from a second axial end of said stator, the electricmachine further comprising: at least one terminal, said at least oneterminal electrically connected to at least one said end turn.
 5. Anelectric machine comprising: a stator having a substantially cylindricalinterior, said stator comprising a plurality of stator slots; a firstplurality of hairpin conductors positioned in said stator slots in afull pitch arrangement to form a first winding set, said first windingset arranged to carry at least one electrical phase, said firstplurality of hairpin conductors each including an end turn and two legsof equal length, said legs of equal length of each of said firstplurality of hairpin conductors bent outward to generally follow thecircumference of said stator; a second plurality of hairpin conductorspositioned in said stator slots in a full pitch arrangement to form asecond winding set, said second winding set arranged to carry said atleast one electrical phase, said second winding set being substantiallyconcentric with said first winding set, said second winding set beingoffset by at least one slot with respect to said first winding set, saidsecond plurality of hairpin conductors each including an end turn andtwo legs of equal length, said legs of equal length of each of saidsecond plurality of hairpin conductors bent outward to generally followthe circumference of said stator; and at least one electrical connectionbetween said first winding set and said second winding set, said atleast one electrical connection made by joining at least one leg of saidfirst plurality of hairpin conductors to at least one adjacent leg ofsaid second plurality of hairpin conductors.
 6. The electric machine ofclaim 5, further comprising: at least one other plurality of hairpinconductors positioned in said stator slots in a full pitch arrangementto form at least one other winding set, said at least one other windingset being substantially concentric with said first winding set.
 7. Theelectric machine of claim 5, further comprising: hairpin conductorinsulation, said hairpin conductor insulation applied to at least one ofsaid first plurality of hairpin conductors before said first pluralityof hairpin conductors are positioned in said stator slots.
 8. Theelectric machine of claim 5, wherein said first plurality of hairpinconductors and said second plurality of hairpin conductors arepositioned in said stator slots such that said end turns protrude from afirst axial end of said stator and said legs protrude from a secondaxial end of said stator, the electric machine further comprising: atleast one terminal, said at least one terminal electrically connected toat least one said end turn.
 9. A hairpin wound stator for an electricmachine, the stator comprising: a plurality of partially closed statorslots; a first winding set positioned in said stator slots, said firstwinding set comprising a first plurality of hairpins forming a firstlayer of conductors in said stator slots and a second layer ofconductors in said stator slots, said first plurality of hairpins eachincluding one end turn joining two legs with leg ends and each leg endbent to a desired configuration to form adjacent leg ends between saidfirst layer of conductors and said second layer of conductors; a secondwinding set positioned in said stator slots, said second winding setcomprising a second plurality of hairpins forming a third layer ofconductors in said stator slots and a fourth layer of conductors in saidstator slots, said second plurality of hairpins each including one endturn joining two legs with leg ends and each leg end bent to a desiredconfiguration to form adjacent leg ends between (i) said second layer ofconductors and said third layer of conductors and (ii) said third layerof conductors and said fourth layer of conductors; wherein said secondwinding set is joined to said first winding set by connecting at leastone of said adjacent leg ends between said second layer of conductorsand said third layer of conductors; and at least one terminal, said atleast one terminal electrically connected to at least one said end turn.10. The electric machine of claim 9, further comprising: at least oneother winding set positioned in said stator slots.
 11. The hairpin woundstator of claim 9, further comprising: hairpin conductor insulation,said hairpin conductor insulation applied to at least a one of saidfirst plurality of hairpins before said first plurality of hairpins arepositioned in said stator slots.